f50lx cap 01 (info generali)
TRANSCRIPT
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1. GENERAL INFORMATION
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FILLY LX 50
Location of Engine Serial Number
1
ENGINE SERIAL NUMBER
1ENGINE SERIAL NUMBER...................1- 1 LUBRICATION POINTS.......................1-13SPECIFICATIONS...................................1- 2 CABLE & HARNESS ROUTING ............1-15
SERVICE PRECAUTIONS ......................1- 3 WIRING DIAGRAM ...............................1-20
TORQUE VALUES ..................................1-11 TROUBLESHOOTUNG..........................1-21
SPECIAL TOOLS .....................................1-12
Filly LX 50
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FILLY LX 50
SPECIFICATIONS
Motorcycle Name & Type Filly LX 50
Name & Model No. SD10BB
Overall length (mm) 1720Overall width (mm) 625
Overall height (mm) 1035
Wheel base (mm) 1200
Engine type O.H.C.
Displacement 49.5cc
Fuel Used 92# nonleaded gasoline
Front wheel 34
Net weight (kg) Rear wheel 48
Total 82
Front wheel 35
Gross weight(kg) Rear wheel 50
Total 85
Front wheel 90/90-10 50JTires
Rear wheel 100/80-10 53J
Ground clearance (mm) 110
Perform
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Braking distance (m)7.9 (Initial speed
40km/h)
ance Min. turning radius (m) 1.8
Starting systemStarting motor &
kick starterType Gasoline, 4-stroke
Cylinder arrangement Single cylinder
Combustion chamber type Semi-sphere
Valve arrangement O.H.C.
Bore x stroke (mm) f39.0 x 41.4
Compression ratio 10.5Compression pressure(kg/cm_-rpm) 14
Max. output 2.208/8000kw/(r/min
)
Max. torque 0.3/6500kg m/rpmOpen 3
PortIntake
Close 7
Engine
timing
Open 9Exhaust
Close 1
Valve clearance Intake 0.04
(cold) (mm) Exhaust 0.04
Idle speed (rpm) 1900 100rpm
Lubrication typeForced pressure &
wet sump
Oil pump type Inner/outer rotor type
Lu
brication
Sy
stem
Oil filter type Full-flow filtration
Oil capacity 0.85 liter
Cooling Type Forced air cooling
Air cleaner type & No Paper element, wet
Fuel capacity 6.1 liter
Type CVK
Piston dia. (mm)
Venturi
dia.(mm)
f17equivalent
Carburetor
Throttle type Butterfly type
Type CDI
Ignition timing BTDC28/4000rpm
Contact breaker Non-contact pointtype
Spark plug NGK
C7HSA
Spark plug gap 0.6_ 0.7mm
Battery Capacity 12V4AH
Clutch Type Dry multi-disc clutch
Type Non-stage transmission
Operation Automatic
centrifugaltype
Type Two-stage reduction
Reduction 1st 0.8-3.1
ratio 2nd 11.05
Front Caster angle 27
Axle Trail length
Tire ressure Front 1.75(kg/cm_) Rear 2.25
Turning Left 45
angle Right 45
Front DISK (160mm)Brake system
type Rear Drum (110mm)
brake
Front TELESCOPESuspension typeRear Unit Swing
Front 70Shock absorberdistance
Rear 66
Frame type Under Bone
FuelSystem
Elec
trical
IgnitionSystem
PowerD
riveSystem
Transm
is-
sionG
ear
Reduction
Gear
MovingDevice
Device
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FILLY LX 50
SERVICE PRECAUTIONS
nMake sure to install new gaskets, O-rings,circlips, cotter pins, etc. when
reassembling.
nWhen tightening bolts or nuts, begin withlarger-diameter to smaller ones at severaltimes, and tighten to the specified torquediagonally.
n Use genuine parts and lubricants
.
nWhen servicing the motorcycle, be sure touse special tools for removal andinstallation.
n After disassembly, clean removed parts.Lubricate sliding surfaces with engine oil
before reassembly.
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n Apply or add designated greases andlubricants to the specified lubrication
points.
n After reassembly, check all parts for
proper tightening and operation.
nWhen two persons work together, payattention to the mutual working safety.
n Disconnect the battery negative (-) terminalbefore operation.
nWhen using a spanner or other tools, makesure not to damage the motorcycle surface.
n After operation, check all connectingpoints, fasteners, and lines for properconnection and installation.
nWhen connecting the battery, the positive(+) terminal must be connected first.
n After connection, apply grease to thebattery terminals.
n Terminal caps shall be installed securely.
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n If the fuse is burned out, find the cause andrepair it. Replace it with a new oneaccording to the specified capacity.
n After operation, terminal caps shall beinstalled securely.
nWhen taking out the connector, the lock onthe connector shall be released beforeoperation.
n Hold the connector body when connectingor disconnecting it.
n Do not pull the connector wire.
n Check if any connector terminal is bending,protruding or loose.
ConfirmCapacity
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n The connector shall be insertedcompletely.
n If the double connector has a lock, lock
it at the correct position.n Check if there is any loose wire.
n Before connecting a terminal, check for
damaged terminal cover or loose negativeterminal.
n Check the double connector cover forproper coverage and installation.
n Insert the terminal completely.
n Check the terminal cover for propercoverage.
n Do not make the terminal cover openingface up.
n Secure wire harnesses to the frame withtheir respective wire bands at thedesignated locations.Tighten the bands so that only theinsulated surfaces contact the wireharnesses.
Snapping!
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n After clamping, check each wire to makesure it is secure.
.
n Do not squeeze wires against the weld orits clamp
n After clamping, check each harness to makesure that it is not interfering with any
moving or sliding parts.
nWhen fixing the wire harnesses, do notmake it contact the parts which willgenerate high heat.
n Route wire harnesses to avoid sharp edgesor corners. Avoid the projected ends of
bolts and screws.n Route wire harnesses passing through the
side of bolts and screws. Avoid theprojected ends of bolts and screws.
No Contact
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FILLY LX 50
n Route harnesses so they are neitherpulled tight nor have excessive slack.
.
n Protect wires and harnesses with electricaltape or tube if they contact a sharp edge orcorner
nWhen rubber protecting cover is used toprotect the wire harnesses, it shall beinstalled securely.
n Do not break the sheath of wire.
n If a wire or harness is with a broken sheath,repair by wrapping it with protective tapeor replace it.
nWhen installing other parts, do not press orsqueeze the wires.
Do notpull too
Do not press orsqueeze the wire.
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n After routing, check that the wire harnessesare not twisted or kinked.
nWire harnesses routed along with handlebarshould not be pulled tight, have excessiveslack or interfere with adjacent orsurrounding parts in all steering positions.
nWhen a testing device is used, make sure tounderstand the operating methodsthoroughly and operate according to theoperating instructions.
n Be careful not to drop any parts.
nWhen rust is found on a terminal, removethe rust with sand paper or equivalent
before connecting.
n Do not bend or twist control cables.Damaged control cables will not operatesmoothly and may stick or bind.
Do you understandthe instrument? Isthe instrument setcorrectly?
Remove Rust
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FILLY LX 50
n Symbols:
The following symbols represent theservicing methods and cautions included in
this service manual.
: Apply engine oil to thespecified points. (Usedesignated engine oil forlubrication.)
: Apply grease for lubrication.
: Transmission Gear Oil (90#)
: Use special tool.
: Caution
: Warning
(12-3) :Refer to page 12-3.
Engine Oil
Grease
Gear Oil
Special
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FILLY LX 50
TORQUE VALUES
STANDARD TORQUE VALUES
Item Torque (kg-m) Item Torque (kg-m)
5mm bolt, nut
6mm bolt, nut
8mm bolt, nut
10mm bolt, nut
12mm bolt, nut
0.45-0.6
0.6-1.2
1.8-2.5
3.0-4.0
5.0-6.0
5mm screw
6mm screw, SH bolt
6mm flange bolt, nut
8mm flange bolt, nut
10mm flange bolt, nut
0.35-0.5
0.7-1.1
1.0-1.4
2.4-3.0
3.5-4.5
Torque specifications listed below are for important fasteners.
ENGINE
Item Qty Thread dia.(mm) Torque (kg-m) Remarks
Cylinder head bolt A
Cylinder head bolt B
Oil filter screen cap
Exhaust muffler lock bolt
Cylinder head flange nut
Valve adjusting lock nut
Cam chain tensioner slipper bolt
Oil bolt
Clutch outer nut
Clutch drive plate nut
Starter motor mounting bolt
Oil pump bolt
Drive face nut
Spark plug
A.C. generator stator bolt
Cam chain tensioner bolt
2
4
1
2
4
2
1
1
1
1
2
3
1
1
2
1
6
6
30
6
7
3
8
8
10
28
6
4
10
10
6
6
0.7-1.1
0.7-1.1
1.0-2.0
0.7-1.1
1.2-1.6
0.07-0.09
0.4-0.7
1.1-1.5
3.5-4.5
5.0-6.0
0.8-1.2
0.1-0.3
5.5-6.5
1.0-1.4
0.8-1.2
0.8-1.2
Double end bolt
Double end bolt
Apply oil to
threads
FRAME
Item Qty Thread dia.(mm) Torque (kg-m) Remarks
Steering stem lock nut
Front axle nut
Rear axle nut
Rear shock absorber upper bolt
Rear shock absorber lower bolt
Speedometer cable set screw
Rear shock absorber lock nut
1
1
1
1
1
1
1
25.4
10
14
10
8
5
8
8.0-12.0
5.0-7.0
11.0-13.0
4.0-5.0
2.0-3.0
0.45-0.6
3.0-3.6
U-nut
U-nut
U-nut
Apply locking agent
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FILLY LX 50
SPECIAL TOOLS
Tool Name Tool No. Remarks
Ref.
Page
10-310-4
Bearingpuller10.12.15.18 mm
E03710.12.15.18mm
bearing 12-6
Bushingremover L
E03211102
bush
Bushingremover S
EO1911203
bush rear
Crankshaftbearing E030
91005radial
Crankshaftprotector E029 13000crankshaft
Clutchspringcompressor
E0272301adriven
pully assy
9-99-12
Cushionassemble F004
52400cushion 13-4
Flywheelholder
E017
31110flywheelcomp.2310a pullyassy driven
9-59-99-1314-714-9
Flywheelpuller E002 Left handthread 14-7
Longsocket F002
50306steering
12-2112-22
Oil sealbearing E014
Oil seal &bearing
Tool boox E033Specialtools
Tappetadjuster
E03690012screw 3-5
7-7Valvespring
compressor
E038Valvespring
7-8
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1. GENERAL INFORMATION
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FILLY LX 50
LUBRICATION POINTS
ENGINE
Lubrication Points Lubricant
Valve guide/valve stem movable part
Cam lobes
Valve rocker arm friction surface
Cam chain
Cylinder lock bolt and nut
Piston surroundings and piston ring grooves
Piston pin surroundings
Cylinder inside wall
Connecting rod/piston pin hole
Connecting rod big end
Crankshaft R/L side oil seal
Starter reduction gear engaging part
Countershaft gear engaging part
Final gear engaging partBearing movable part
O-ring face
Oil seal lip
Genuine KYMCO Engine Oil (SAE15W-40)
API-SG Engine Oil
Starter idle gear
Friction sp ring movable part /shaft movable part
Shaft movable grooved part
Kick starter spindle movable part
High-temperature resistant grease
A.C. generator connector
Transmission case breather tubeAdhesive
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FRAME
The following is the lubrication points for the frame.Use general purpose grease for parts not listed.Apply clean engine oil or grease to cables and movable parts not specified.This will avoid abnormal noise and rise the durability of the motorcycle.
Rear Wheel BearingsMain Stand Pivot
Speedometer Gear/ Front Wheel
Bearings/ Brake Cam/ Anchor Pin/Front Shock Absorber LowerMount Bushings/Pivot
Grease Grease
Grease
Engine Oil
Rear Brake Cable
Brake Cam/
Anchor Pin
Grease
Grease
Front Brake LeverPivot
Front Brake Cable/Speedometer Cable/Throttle Cable
Engine/ Oil
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FILLY LX 50
CABLE & HARNESS ROUTING
Front Stop Switch Wire
Rear Stop Switch Wire
Throttle Cable
Regulator/Rectifier
Rear Brake Cable
Speedometer Cable
Horn
Ignition Switch
Winker
Headlight Resistor
Front Brake Fluid Tube
Brake Master Cylinder
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FILLY LX 50
Regulator/Rectifier
Speedometer Cable
Ignition Switch
Fuel Filler
Throttle Grip
Rear Brake Lever
Fuel TankInlet Tube
Fuel TankBreather Tube
Front Brake Fluid Tube
Fuel Tank
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Starter Relay
Fuse
Battery (+) Cable
Battery (-) Cable
CDI Unit
Battery (+) Cable
Battery (-) Cable
CDI Unit
Ignition Coil
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Throttle Cable
Fuel VaporRecovery Tube
Vacuum Tee
CarburetorOverflow Tube
Fuel Tube
Crankcase BreathTube
Ignition CoilPrimary Wire
Ignition Wire
Fuel
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FILLY LX 50
Throttle Cable
Fuel Tube
Vacuum Tube
Auto Bystarter
Fuel Unit
Crankcase BreatherTube
Ignition Coil
Fuel VaporRecovery Tube
Wire Harness
Crankcase BreatherTube
Throttle Cable
Vacuum Tube
Fuel Filter
Fuel
Pump
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FILLY LX 50
WIRING DIAGRAM
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FILLY LX 50
TROUBLESHOOTING
ENGINE WILL NOT START OR IS HARD TO START
Empty fuel tankClogged fuel line between fueltank and carburetorClogged float oil passageClogged fuel tank cap breatherholeClogged fuel filter
Clogged fuel strainerFaulty auto fuel valve
Faulty spark plugFouled spark plugFaulty CDI unitFaulty pulser coilBroken or shorted ignition coilBroken or shorted high-
tensionwireFaulty ignition switch
Faulty starter clutchValve clearance too smallImproper valve and seat contactWorn cylinder, piston and pistonringsLeaking cylinder head gasketSeized valveImproper valve timing
Faulty auto bystarterAir leaking through intake
pipeIncorrect ignition timingIncorrectly adjusted pilot screw
Flooded carburetorFaulty auto bystarterThrottle valve excessively
open
Check if fuel reachescarburetor byloosening drain screw
Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground
Inspection/Adjustment Probable Cause
Spark jumps
Normalcompression
Engine does not
fire
Weak or no spark
Low or nocompression
Engine fires but
does not start
Test cylindercompression
Start engine by follow-ing normal starting
procedure
Remove spark plug andinspect again
Symptom
Fuel reachescarburetor
Fuel does notreach carburetor
Wet spark plugDry spark plug
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FILLY LX 50
ENGINE LACKS POWER
Clogged air cleanerPoor quality fuel (Restricted)Clogged fuel tank cap breather holeClogged exhaust mufflerFaulty auto bystarterSplit carburetor vacuum pistondiaphragmFaulty auto fuel valve
Faulty CDI unitFaulty pulser coil
Improper valve clearanceadjustmentWorn valve seat (valve stem tooprotruding
Improper valve and seat contactWorn cylinder and piston ringsLeaking cylinder head gasketImproper valve timing
Clogged carburetor jets
Fouled spark plugIncorrect heat range plug
Oil level too highOil level too lowOil not changed
Clogged oil pipe
Faulty oil pump
Worn cylinder and piston ringsMixture too leanPoor quality fuelExcessive carbon buildup incombustion chamberIgnition timing too early
Excessive carbon build-up incombustion chamberPoor quality fuel
Clutch slippingMixture too leanIgnition timing too early
Start engine and acceleratelightly for observation
Inspection/Adjustment Symptom Probable Cause
Engine speedincreases
Correct timing
Engine speed does notincrease sufficiently
Incorrect timing
Check ignition timingusing a timing light
Test cylinder compression
Check carburetor forclogging
Rapidly accelerate or runat high speed
Remove spark plug andinspect
Check if engine overheats
Check valve clearance
Correct Incorrect
Normalcompression
Abnormalcompression
Remove oil dipstick andcheck oil level and condition
Remove cylinder head oilpipe bolt and inspect
Engine overheatsEngine does notoverheats
Plug not fouled ordiscolored
Plug fouled ordiscolored
Correct and notcontaminated
Incorrect orcontaminated
Valve train lubricatedproperly Valve train notlubricated properly
Engine does not knock Engine knocks
Not clogged Clogged
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FILLY LX 50
POOR PERFORMANCE (ESPECIALLY AT IDLE AND LOW SPEEDS)
Faulty CDI unit
Faulty pulser coil
Mixture too rich (turn screwout)Mixture too lean (turn screw
in)
Deteriorated O-ringCarburetor not securelytightened
Damaged insulator rubberBroken vacuum tube
Faulty or fouled spark plugFaulty CDI unitFaulty A.C. generatorFaulty ignition coilBroken or shorted spark plugwireFaulty ignition switch
Faulty air cut-off valveDamaged vacuum tubeClogged or damaged air venthole
Remove spark plugand install it intospark plug cap to testspark by connecting itto engine ground
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check air cut-off
Check carburetorgasket for air leaks
Check carburetor pilot
screw adjustment
Correct timing Incorrect timing
Correctly adjusted
No air leak Air leaks
Good sparkWeak or inter-mittent spark
Good Faulty
Incorrectly
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FILLY LX 50
POOR PERFORMANCE (AT HIGH SPEED)
Faulty CDI unit
Faulty pulser coil
Improperly adjusted valveclearanceWorn camshaftWorn valve seat
Empty fuel tankClogged fuel tube or filterFaulty charcoal canisterFaulty auto fuel valve
Clean and unclog
Cam timing gear aligningmarks not aligned
Faulty spring
Inspection/Adjustment Symptom Probable Cause
Check ignition timing
Check carburetor jetsfor clogging
Check fuel pump forfuel supply
Correct timing Incorrect timing
Check valve springtension
Check valve clearance
Fuel flows freelyFuel flow restricted
Correct Incorrect
Not clogged Clogged
Correctly adjusted Incorrectly adjusted
Not weakened Weak spring
Check valve timing
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FILLY LX 50
POOR CHARGING (BATTERY OVER DISCHARGING OR OVERCHARGING)
Undercharging
Dead battery
Faulty battery
Faulty A.C. generator coilBroken yellow wireLoose connector
Broken red wire
Faulty regulator/rectifier
Poorly connected coupler
Faulty A.C. generator
Overcharging
Broken green wire
Poorly connected coupler
Faulty regulator/rectifier
Start engine and testlimit voltage between
battery terminals
Connect battery (+)wire toregulator/rectifiercoupler red wire and
battery (-) wire to engineground and test voltage
Inspection/Adjustment
Inspection/Adjustment
Symptom
Symptom
Probable Cause
Probable Cause
Normal voltage
Battery hasvoltage withi nition switch
Normal
Voltage does notincrease
Battery has novoltage withi nition switch
Resistance too
Normal voltage No voltage
Measure resistance
between AC generatorcoil terminals
Normal Abnormal
Check
regulator/rectifiercoupler for looseconnection
Normal Abnormal
Connect battery (+)
wire toregulator/rectifiercoupler green wire and
battery (-) wire to engineground and test voltage
Checkregulator/rectifiercoupler for looseconnection
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1. GENERAL INFORMATION FILLY LX 50
NO SPARK AT SPARK PLUG
Faulty old spark plug
Loose spark plug cap
Poorly connected coupler
Faulty ignition switchFaulty pulser coilFaulty ignition coil
Broken wire harnessPoorly connected coupler
Faulty CDI unit
Faulty ignition coil
Replace with a newspark plug and inspectagain
Check CDI unitcoupler for looseness
Inspection/Adjustment Symptom Probable Cause
Normal
Abnormal
Normal
Abnormal
Normal Abnormal
Abnormal
Measure resistancebetween CDI unitcoupler wire terminals
Check related parts
Check ignition coil
with a CDI unit tester
Weak or no spark
Not loose
Good spark
Loose
Good Good
Check spark plug capand high-tension wirefor looseness
Check CDI unit with aCDI unit tester